Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

CHAPTER 4
REQUIREMENT OF STEEL FOR 11TH AND 12TH PLAN
In this Chapter, an assessment has been made of the requirement of material specifically different types of steel for hydro & thermal power plants and power system network planned for 11th and 12th Plan. A detailed exercise has been carried out to assess the requirement of both type of steel i.e. imported & indigenous. An assessment has also been made of the requirement of copper and aluminium required for transmission lines. These details shall provide valuable inputs for equipment and material manufacturers and guide them to plan their production capacities accordingly. In case of thermal power stations, steel requirement for different units of generation plants i.e. boiler, coal handling unit, ash handling unit, condenser, pulveriser etc has been estimated. For a hydro power plant, estimation has been done for steel requirement in civil works as well as electro mechanical equipments/systems in the power house. Transmission system requirement corresponding to the planned generation capacity addition has also been worked out. Material requirement for this transmission system, including generation switchyard, substation and transmission lines, including towers, line conductors & earth wires have also been assessed in this Chapter. 4.1 STEEL REQUIREMENT FOR GENERATING STATIONS

4.1.1 Hydro Power Plants In case of hydro plants, norms for requirement of steel i.e. Tonnes/MW have been formulated based on details furnished by NHPC and BHEL of actual project setup. These norms include steel requirement for Electrical & Mechanical package (Turbine & Generator) as well as for civil works. Norms are as given below: Table 4.1 Tonnes/MW Steel Structural Steel Reinforcement Steel Norms 34 93

Based on the above average requirement per MW, the steel requirement for the 11 th Plan Hydro projects works out to be given as under: Table 4.2 Steel Structural Steel Reinforcement Steel Total 11 Plan (17189 MW) 5.8 16.0 21.8
4. 1
th

Lakhs Tonnes 12 Plan (30000 MW) Total 10.2 16.0 27.9 43.9 38.1 59.9
th

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

4.1.2 Thermal Power Plants Requirement of steel (Imported & Indigenous ) for thermal power projects coming up in 11th Plan is calculated on the basis of detailed steel requirement for typical 2x500 MW coal based unit , provided by BHEL (Given in Appendix 1). For Coal/Lignite based projects, steel requirement per MW has been worked out and based on this per MW norm, the requirement of steel for the total coal based thermal capacity has been assessed. For gas based projects, norms for steel requirement per MW have been assumed to be 50% of coal based project for the applicable items as has been noted in case of past installations. Also in case of gas based plants items such as furnace, coal handling plant, Electrostatic precipitators etc. are not required and hence have not been considered. During 11th Plan, total thermal capacity addition planned is 46,114 MW comprising of about 44,000 MW of coal/lignite based plants and 2114 MW of gas based plants. Similarly for 12th Plan, thermal capacity addition planned is 44,500 MW. Details of steel requirement for different equipments/ systems for the 11th and 12th Plan coal based thermal projects are furnished in Table 4.3.

4. 2

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Table 4.3 Estimated Quantity of Steel for 11th and 12th Plan coal/ lignite Based Projects
Sl.No . Equipment/ System Type of steel used 1 1.1 1.2 Boiler Drum 20108 54912 182160 257180 0 1320 1312916 196196 1510432 236060 21428 1367828 378356 1767612 236060 93192 698720 1961520 58432 31900 68200 616000 151800 16016 6160 5280 179256 10120 4180 15224 616 616 2156 2640 35552 5,746,44 4 20337 55536 184230 260103 0 94251 324405 0 59096 13350 0 0 73158 1780 1780 0 76718 6230 3827 623 89 0 1113 979 12861 840783 1335 1327836 198426 1527596 238743 0 382255 1983810 0 18913 68975 623000 80367 14418 4450 5340 104575 4005 401 14774 534 623 1068 1691 23096 4970962 21672 1383372 382656 1787699 238743 94251 706660 1983810 59096 32263 68975 623000 153525 16198 6230 5340 181293 10235 4228 15397 623 623 2181 2670 35956 5811745 11th Plan coal based 44,000 MW (MT) Imported Indigenous Total 12th Plan coal based 44500 MW (MT) Imported Indigenous Total

Structures/Non-Pressure parts 1.3 Pressure Parts Total (Boiler) 2 3 4 5 6 Low Pressure Piping High Pressure/PC piping

93192 0 Electrostatic Precipitator 320760 377960 Main and Aux.Buildings 0 1961520 PowerTransformers (CRGO) 58432 0 7 Motors 13200 18700 8 Switchyard 0 68200 9 Coal Handling Plant 0 616000 10 Turbine/Gen./Condenser 10.1 Plates 72336 79464 10.2 Rounds 1760 14256 10.3 Structural Steel, IS 2062 1760 4400 10.4 Bloom,Class2 & Class 3 0 5280 Total(Turbine/generator/condense r 75856 103400 11 Pumps/Heat Exchangers/Drive-Turbines and Pulverisers 11.1 LP and HP Heaters 6160 3960 11.2 Deaerators 3784 396 11.3 Pulverisers 616 14608 11.4 Drive Turbines 88 528 11.5 Structurals 0 616 11.6 Bar Stock 1100 1056 11.7 Pipes 968 1672 Sub Total(Pumps etc.) 12716 22836 GRAND TOTAL (MT) 831,336 4,915,108

The detailed steel requirement for 11th and 12th plan coal based projects is given in Appendix 2. Details of steel requirement for different equipments/ systems for the 11th and 12th Plan Gas based thermal projects are furnished in Table 4.4

4. 3

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

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Requirement of Equipment & Material for Development of Power Sector

Table 4.4 Estimated Quantity of Steel for 11th Plan Gas Based Projects
Sl. No 1. 1.1 1.2 1.3 2. 3. 4. 5. 6. 7. 8. 8.1 8.2 8.3 8.4 Equipment/ Systm Type of steel used 11thPlan Gas- 2114 MW (MT)

Imported Indigenous Total

9 9.1 9.2 9.3 9.4 9.5 9.6

Boiler Drum: 483 32 515 Structures/NonPressure parts 1319 31540 32859 Sub-total for Pressure Parts 4376 4713 9089 Total(Boiler) 6178 36285 42463 LP Piping 0 5671 5671 HP/PC Piping 2239 0 2239 Main and Aux.Buildings 0 47121 47121 Power Transformers (CRGO) 2807 0 2807 Motors 317 449 766 Switchyard 0 3277 3277 Turbine/Gen./Condenser Plates 1738 1909 3647 Rounds 42 342 385 Structural Steel, IS 2062 42 106 148 Bloom,Class2 & Class 3 0 127 127 Total(Turbine/gen/c ondenser) 1822 2484 4306 Pumps/Heat Exchangers/Drive-Turbines and Pulverisers LP and HP Heaters 148 95 243 Deaerators 91 10 100 Drive Turbines 2 13 15 Structurals 0 15 15 Bar Stock 26 25 51 Pipes 23 40 63 Sub Total(Pumps) 291 198 488 Grand Total (MT) 13654 95484 109138

The detailed steel requirement for 11th plan Gas based projects is given in Appendix 3. A Summary of the total steel requirement for thermal projects coming up in 11 th & 12th Plan is furnished in Table 4.5 below:

4. 4

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Table- 4.5 Summary of Total Steel Requirement for 11th &12th Plan Thermal Power Projects 11th Plan (MT) Coal Based Power Projects Gas Based Power Projects Total 57,46,444 1,09,138 58,55,582 12th Plan (MT) 58,11,745 58,11,745 Total (MT) 1,15,58,189 1,09,138 1,16,67,327

As evident from above, for 11th Plan, approximately 58,55,582 Mt of steel is expected to be required for the planned thermal projects. Similarly, approximately 58,11,745 MT of steel is expected to be required for the thermal projects coming up in 12th Plan. 4.1.3 Nuclear Power Projects Assessment of steel for Nuclear Power Plants is based on requirement of steel for coal based plants. In case of nuclear plants, need for steel for coal handling system, boiler, ESP etc is eliminated whereas amount of steel for turbine etc. is increased. Assuming the effect of these two factors approximately equal, the norms for the steel requirement for nuclear power plants is taken to be same as that of coal based plants. Considering the above, the steel requirement for Nuclear Projects is as under: Table 4.6 (Lakh Tonnes)
Imported Steel Indigenous Steel 11th Plan (3160 MW) 12th Plan (12000 MW) 0.6 2.3 3.5 13.4 Total Steel 4.1 15.7

4.2

STEEL REQUIREMENT FOR POWER SYSTEM

4. 5

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

As per the transmission expansion plan, transmission lines and substation of 765 kV, 400 kV, 220kV and 132kVand below are to be added to the existing power grid during the 11th and 12th Plans. Steel requirement for Towers, conductors, earth wires, power transformers and sub-stations is calculated as per the design norms for different transmission voltage levels.

4. 6

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

4.2.1

Requirement of Steel for Tower for 11th And 12th Plan

As per the Transmission plans, the number of circuit kMs of transmission lines at various voltage levels has been estimated. Based on Statistics, norms for steel requirement for transmission towers at 765kV, 500kV, 400kV, and 220kV and 132kV voltage levels have been evolved in terms of MT per circuit kM at each of these voltage levels. The requirement of steel is then assessed based on the total circuit kms expected in each Plan. Details of norms for steel requirement as well as total requirement during 11 th and 12th Plans for each voltage level along with the type of steels used i.e. MS & HTS.are furnished in Table 4.6. Table-4.7 Requirement of Steel for Towers
Total All India Total All India (11th Plan) (12th Plan) Norms for weight of Total Total steel for Weight of Weight of ckt. ckt. Towers steel for steel for Km Km MT/Km towers towers (MT) (MT) 65 3200 208000 3200 208000 38.3 5400 206820 5400 206820 23.5 44440 10.1 23000 9.1 20000 1044340 44440 232300 23000 182000 20000 1873460 Type of Steel used HTS (40% of Total weight) (MT)
166400 165456 835472

Line S.No Voltage (kV)

MS (MT)
249600 248184

1 2 3 4 5

765 500 HVDC 400 220 132 TOTAL

1044340 1253208 232300 464600 182000 364000 1873460 2579592

1167328

NOTE: Structural steel angle section manufactured according to the latest IS: 8081976(Part V & VI) and tested according to the latest edition of IS: 2062-1992 or any other equivalent or superior International Standards will be used in the fabrication of the towers having its yield strength not less than 250 N/sq.mm and stress value of high tensile steel (Fe-490 High Tensile and Fe -540 High Tensile) grade according to IS: 8500 -1992. 4.2.2 Requirement of Aluminium and Steel for Conductor and Earth Wire for 11th and 12th Plan A. Requirement of Aluminium and Steel for Conductor and Earth Wire for 11th Plan The requirement of Aluminium and Steel for conductor and earth wires has been assessed based on norms in terms of MT per ckt kM at each voltage level and the total number of ckt kMs planned during the 11th and 12th Plans. Tables 4.8 and 4.9 furnish the requirement of aluminium & steel for the conductor and earth wire for the 11 th and 12th Plans respectively.

4. 7

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Table-4.8 Requirement of Aluminium and Steel for Conductor and Earth Wire for 11th Plan
Norms for Weight of Material for Total Voltage (kV) Transmission Lines Ckt.kM (MT/ckt kM) Aluminum Steel 765 23.14 4.64 3200 500 (HVDC) 15.43 3.50 5400 400 8.87 4.53 44440 220 3.60 1.79 23000 132 1.78 1.64 20000 Total

S. No. 1 2 3 4 5 6

Total All India Weight (MT/ckt kM) Aluminum

74048 83322 394183 82800 35600 669953

Steel
14848 18900 201313 41170 32800 309031

B. Requirement of Aluminium and Steel for Conductor and Earth Wire for 12th Plan Table 4.9 shows the requirement of aluminium & steel for the conductor and earth wire for the 11th Plan Table-4.9 Requirement of Aluminium and Steel for Conductor and Earth Wire for 12th Plan
Norms for Weight of Material for Total Total All India Weight S. No. Voltage (kV) Transmission Lines Ckt.kM (MT/ckt kM) (MT/ckt kM) Aluminum Steel Aluminum Steel 1 765 23.14 4.64 3200 74048 14848 2 500 (HVDC) 15.43 3.50 5400 83322 18900 3 400 8.87 4.53 44440 394183 201313 4 220 3.60 1.79 23000 82800 41170 5 132 1.78 1.64 20000 35600 32800 6 Total 669953 309031

Note: The Conductor & Earth wire shall comply in all respect with the IS: 398(Part-II)1996, IS: 398 (Part-V) -1992 & IS: 398(Part-II)-1996, IS:2141-1996 latest amendments respectively or any other International standards which ensure equal or higher quality of material. 4.2.3 Requirement of Special Steel -CRGO and Copper for Power Transformers during 11th And 12th Plan An assessment of the requirement of special steel and copper for power transformers is made based on Norms evolved based on Statistics. As per these norms, the requirement in terms of MT per MVA is specified as furnished in Table 4.10 below:

4. 8

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Table- 4.10 Norms for requirement of Special Steel and Copper for power transformers 765 kV CRGO Requirement (MT/MVA) Copper Requirement (MT/MVA) 0.4 0.2 400 kV 0.4 0.2 220kV 0.5 0.3 132kV 0.8 0.5

The total requirement of Special Steel and Copper is worked out based on the Norms and the power transformer capacity at each voltage level planned during the 11th and 12th Plans and is furnished in Table 4.11 below Plan. Table-4.11 Requirement of Special Steel and Copper for Power Transformers
11th Plan (2007-2012) Total CRGO Copper WT MVA WT (inTons) Capacity (inTons) 765 kV 12500 5000 2500 400 kV 44310 17724 8862 220 kV 73700 36850 22110 132 kV 52000 41600 26000 Total required CRGO weight (in Tons) for 11th Plan Total required CRGO weight (in Tons) for 12th Plan Total required Copper weight (in Tons) for 11th Plan Total required Copper weight (in Tons) for 12th Plan Power Transformer Rating 12th Plan (2012-2017) CRGO Copper WT WT (in Tons) (in Tons) 5000 2500 17724 8862 36850 22110 41600 26000

Total MVA Capacity 12500 44310 73700 52000 101174 101174 59472 59472

4.2.4

Estimated Structural Steel Requirement for Substations for 11th and 12th Plan

The requirement of Structural Steel for substations has been assessed based on norms in terms of MT per bay at each voltage level and the total number of bays planned during the 11th and 12th Plans at each voltage level. The total requirement during the 11th and 12th Plan at each voltage level is furnished in Table 4.12:

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REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

Table-4.12 Requirement of Special Steel for Substation

Norms for Special steel requirement for substation (MT/bay) 75 50 35 25 11th Plan Total No. of Bays 62 774 3060 7280 Requirement (MT) 4650 38700 107100 182000 332450 Total No. of Bays 62 774 3060 7280 12th Plan Requirement (MT) 4650 38700 107100 182000 332450 Total Requirement of Special steel for substation (MT) 9300 77400 214200 364000 664900

Voltage level 765 kV 400 kV 220kV 132 kV Total

A Summary of Steel Requirement for major components of power system i.e. towers, conductors, earth wires, power transformers & sub-stations is furnished in Table 4.13. Table-4.13 Summary of Requirement of Steel for Power System 11th Plan (MT) 1873460 309031 1,01,174 3,32,450 2616115 12th Plan (MT) 1873460 309031 1,01,174 3,32,450 2616115 Total (MT) 3746920 618062 202348 664900 5232230

Steel for Tower Steel for conductor & Earth Wire Special Steel -CRGO for Power Transformer Structural Steel for Sub-Stations Total SUMMARY

In this Chapter, an assessment of the requirement of Steel for hydro and thermal Power stations has been made in accordance with the capacities planned during these plans. For hydro stations, requirement has been assessed separately for structural steel and reinforcement steel. For thermal stations assessment has been made separately for coal/ lignite and gas based stations. For generating stations a total requirement of 8.4 Million Tonnes during 11th and 11.2 Million Tons during 12th plan has been assessed. For major components of Power system including substations, towers and transmission lines a total requirement of 2.6 Million tonnes for 11th and 12th Plan each, has been assessed. Steel requirement for 11th & 12th Plan projects is summarised belowIn Lakh Tonnes th th 11 Plan 12 Plan Total Hydro Projects Thermal Projects Nuclear Power System Total
4. 10

21.8 58.5 4.1 26.2 110.6

38.1 58.1 15.7 26.2 138.1

59.9 116.6 19.8 52.4 248.7

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS

Central Electricity Authority

Requirement of Equipment & Material for Development of Power Sector

4. 11

REQUIREMENT OF STEEL FOR 11TH AND 12TH PLANS